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Wire container lid, wire container and wire feeding system

IP.com Disclosure Number: IPCOM000243069D
Publication Date: 2015-Sep-11
Document File: 35 page(s) / 1M

Publishing Venue

The IP.com Prior Art Database


A wire feeding system comprises a wire container including a box having an open upper side, and a wire container lid closing the upper side. The wire container lid includes a front wall having an opening through which wire is to be paid off. A wire outlet guide is attached to the front wall. The wire outlet guide comprises an upper and a lower hole for receiving the wire, the upper and lower holes being defined by a lower ring wall and an upper ring wall, respectively, and being distanced from each other in a wire feeding direction. At least the lower ring wall limits sideward movement of the wire and allows contact with the wire. The holes have a fixed position relative to the front wall. A deflection space bridging the distance between the holes allows sideward deflection of the wire between the ring walls.

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Page 01 of 35

Wire container lid, wire container and wire feeding system

Field of the Invention

  The invention relates to a wire container lid for closing an upper side of a wire box filled with coiled wire, in particular for a welding wire container lid. Furthermore, the invention relates to a wire container, in particular a welding wire


container, and to a wire feeding system comprising a wire container.

  Such wire containers usually comprise coiled steel and aluminum welding wires or metal spray wires or any other wire in applications where the wire is paid out from a large bulk container, pack or drum.



  Wire feeding systems are commonly used for feeding welding wires from a supply source, for example a container in which a significant amount (up to more than one ton) of welding wire is being stored, to a point called welding arc where the welding wire is being deposited through a welding torch, with the purpose of joining metal parts.


  In robotic and automated applications, which are designed to maximize the productivity, it has become a common practice to utilize large bulk packs containing from few hundred kilograms to more than one ton of welding wire. In the initial, and now obsolete automatic setups, the packs were placed on rotating turntables and the rotational movement of the pack helped offset the tension


naturally building on the wire during its payout. For safety and practical reasons, like the shop floor space limitation in plants, the past two decades have seen a wide use of the so called "twist-free" "torsionless" welding wires being paid out from a stationary pack and the wire being deposited into the container through a special winding process. The twist-free winding process has been known for quite 25

some time.

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  The welding wire is drawn from a manufacturing process and runs over rollers, is pulled along by a capstan and is fed into a rotatable cylindrical tube comprising an opening at the bottom or along the cylinder adjacent to the bottom. The wire extends through the tube and out the opening, whereupon it is placed into the storage container.


  The tube protrudes into the storage container and rotates about an axis parallel to the storage container axis. The wire is fed into the tube by the capstan and at a rotational velocity different than the rotational velocity of the tube. A ratio between the rotational velocities of the tube and the capstan defines a loop size diameter of the wire within the storage container.


  The twist-free winding however is not a simple process and it can be negatively affected by a number of variables, like the columnar strength of the wire, its diameter or its surface condition. In particular, aluminum welding wires are difficult to become plastically deformed and pre-twisted, because of their elasticity; moreover their rougher surface condition increases the friction and


complicates the feeding through the conduit guiding the wire into the pack. A...